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Non-woven fibrous product
Resin-impregnated foam materials and methods Sandvig, T.C., Bartizal, D.C., Scholz, M.T., Campagna, A.J. and Libbey, C.J. (Minnesota Mining and Manufacturing Company, St Paul, MN, USA) US Pat 4 888 225 (19 December 1989) A laminating material for mounting a walking heel to an orthopaedic cast consists of an open-celled foam sheet impregnated with a curable prepolymer resin. The whole on curing becomes rigid and weight bearing so as to provide adequate support between the heel and the cast. Composite laminates comprising matrix bound plies having interlocked transverse fibres and a method of making the same Sidles, R. (The B.F. Goodrich Company, Akron, OH, USA) US Pat 4 888 228 (19 December 1989) A composite is described of at least two layers with fibres passing through each layer forming loops on one side. The layers are stacked so that the fibre tips of one layer co-operate with the fibres in the next layer and the spaces between the fibres are impregnated with a binder. Fire resistant composite materials Brew, A.T. (Imperial Chemical Industries plc, London, UK) US Pat 4 888 233 (19 December 1989) A fire and heat resistant composite material consists of a polmeric substrate with a coating of lamellae of chemically delaminated vermiculite and a copolymer of ethylene with a vinyl monomer. Formable fibre composite Smith, G.J., Trask, E.G., Ellis, P., Campbell, B. and Rorie, L. (Gates FormedFibre Products, Inc, Auburn, ME, USA) US Pat 4 888 234 (19 December 1989) A contoured composite is detailed which comprises a sheet of foil tacked onto a nonwoven substrate of fibres of at least one synthetic thermoplastic resin by a needle loom. The substrate takes the shape of a predetermined contour against which the composite is set during at least part of a heating and cooling cycle. Improved non-woven fibrous product Chenoweth, V.C. and Goodsell, R.C. (Guardian Industries Corporation, Northville, MI, USA) US Pat 4 888 235 (19 December 1989) A thermosetting resin is dispersed in a blended matrix of glass and synthetic fibres. The synthetic fibres are selected from polyester, nylon or aramid fibres and contain 2 wt % or less (based on the product weight) of a conductive material. Pulverulent silicon nitride composition including oxidised silicon carbide whiskers Richon, D., De Pous, O. and Fontaine, P. (Battelle Memorial Institute, Geneva, Switzerland) US Pat 4 888 311 (19 December 1989) A composition of Si3N4 powder, 2-15 vol % SiC whiskers and a metal oxide is characterized in that the SiC whiskers are superficially oxidized to form a 2-20 nm layer of SiO2. The composition can be formed into whiskerreinforced articles by high temperature sintering and/or hot isostatic pressing.
334
COMPOSITES. JULY 1991
Non-woven fibrous product Chenoweth, V.C. and Goodsell, R.C. (Guardian Industries Corp, Northville, MI, USA) US Pat 4 889 764 (26 December 1989) The product consists of a thermosetting resin dispersed in a blended matrix of glass fibres and synthetic fibres. The synthetic fibres include homogeneous fibres selected from polyester, nylon, Nomex or Kevlar fibres and bi-component fibres with a polymeric core and sheath, the core having a higher melting point than the sheath. Prepreg sheet for flake lining and lining process using the same Inuzuka, T., Hasegawa, T., Tomikawa, M. and Aoki, S. (Nippon Glass Fiber Co, Ltd, Tsu and Chiyoda Corporation, Yokohama, Japan) US Pat 4 889 766 (26 December 1989) A prepreg sheet consists of a matrix resin containing a curing agent and a thickening agent and 15-40 wt % dispersed flakes of glass, mica, metal or carbon. The flakes are orientated nearly parallel to the surfaces of the sheet and have a thickness of 0.5-10 ~tm, a diameter of 20-1000 [xm (determined assuming that the flakes are circular) and an aspect ratio of 4-1000. Composite material having a slide layer applied by cathode sputtering Bergmann, E. and Brans, J. (Baizers Aktiengeseilschaft, Furstentum, Liechtenstein) US Pat 4 889 772 (26 December 1989) A composite material has at least one cathode sputtered surface layer. This layer consists of a mixture of particles embedded in a matrix of at least one cohesive metallic material with particles of an additional metallic material, the diameters of which vary according to location. The hardness of the layer varies with the particle diameter; regions with small mean particle diameter having high hardness and good load-bearing ability and regions with large mean particle diameter having low hardness and good embedding capacity. SiC-AI20 a composite sintered bodies and method of producing the same Niihara, K. and Nakahira, A. (NGK Insulators, Ltd, Nagoya, Japan) US Pat 4 889 834 (26 December 1989) A composite sintered body with a fracture toughness of not less than 5 MN m -3~2 consists of a matrix of AI20 3 grains less than 5 ~tm in size with 2-10 tool% SiC grains dispersed inside individual Al20 3 grains. The SiC grains are less than 0.5 ~m in size. Composite material containing a layered silicate Usuki, A., Mizutani, Fukushima, Y., Fujimoto, M., Fukumori, K., Kojima, Y., Sato, N., Kurauchi, T. and Kamigaito, O. (Kabushiki Kaisha Toyota Chuo Kenkyusho, Aicha, Japan) US Pat 4 889 885 (26 December 1989) A composite material comprises at least one resin with a layered silicate uniformly dispersed in the resin. The resin is selected from the group consisting of a vinyl-based polymeric compound, a thermosetting resin and a rubber, and the silicate has a layer thickness of 0.7-1.2 nm and an interlayer distance of 3 nm. At least one resin is connected to the layered silicate through an intermediate there between.
Titanium diboride-based composite articles with improved fracture toughness Buljan, S.-T.V. and Geary, E.G. (GTE Laboratories Incorporated, Waltham, MA, USA) US Pat 4 889 935 (26 December 1989) A densified, hard, abrasion-resistant ceramic-matrix composite article consists of a matrix of titanium diboride with not greater than 60 vol % of dispersoids distributed therein. 5-60 vol % of the dispersoids are whiskers or chopped fibres of refractory carbides, nitrides and carbonitrides of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W and solid solutions thereof and 5-55 vol % are particles of the above or whiskers, fibres or particles of hafnium dihoride, tungsten diboride, silicon nitride, alumina, zirconia, hafnia and mixtures and solid solutions of these materials.
PROCESSES Method of manufacturing glass fibre Nishino, A., Mizuno, Y. and Ikeda, M. (Matsushita Electric Industrial Co, Ltd, Osaka, Japan) US Pat 4 885 020 (5 December 1989) Glass is poured into a mould with a polygonal cross-section slit which is 5-50 times larger than the required thickness of the glass fibre. The glass is cooled and removed from the slit to provide a preform which is heated to a temperature of 100°C to 150°C higher than the softening point of the glass so as to obtain a polygonal cross-section glass fibre which is then cooled. Preparation of metal oxide fibres from intercalated graphite fibres McQuillan, B.W. and Reynolds, G.H. (Secretary of the Air Force, Washington, DC, USA) US Pat 4 885 120 (5 December 1989) AICia, ZrCI4 and C12 are intercalated into a graphite fibre by heating the mixture to 250°C for 4 days. The intercalated graphite fibre is heated in air at 800°C to oxidize the carbon and leave a composite aluminium oxidezirconium oxide fibre. Process for preparing self-supporting bodies and products produced thereby Claar, T.D., Mason, S.M., Pochopien, K.P., White, D.R. and Johnson, W.B. (Lanxide Technology Company, LP, Newark, DE, USA) US Pat 4 885 130 (5 December 1989) A parent metal is heated in a substantially inert atmosphere above its melting point. The molten metal is placed in contact with a permeable mass of boron carbide and at least one donor material selected from the group consisting of a carbon donor material and a boron donor material. The temperature is maintained so that the molten metal infiltrates the permeable mass and reacts with the boron carbide to produce at least one boroncontaining compound and with at least one donor material. The reaction is continued until a self-supporting body comprising at least one parent metal boron-containing compound is produced. Process for preparing self~supporting bodies and products produced thereby Newkirk, M.S. (Lanxide Technology Company, LP, Newark, DE, USA) US Pat 4 885 131 (5 December 1989) A parent metal is heated in a substantially inert atmosphere above its melting point. The
334
COMPOSITES. JULY 1991
Non-woven fibrous product Chenoweth, V.C. and Goodsell, R.C. (Guardian Industries Corp, Northville, MI, USA) US Pat 4 889 764 (26 December 1989) The product consists of a thermosetting resin dispersed in a blended matrix of glass fibres and synthetic fibres. The synthetic fibres include homogeneous fibres selected from polyester, nylon, Nomex or Kevlar fibres and bi-component fibres with a polymeric core and sheath, the core having a higher melting point than the sheath. Prepreg sheet for flake lining and lining process using the same Inuzuka, T., Hasegawa, T., Tomikawa, M. and Aoki, S. (Nippon Glass Fiber Co, Ltd, Tsu and Chiyoda Corporation, Yokohama, Japan) US Pat 4 889 766 (26 December 1989) A prepreg sheet consists of a matrix resin containing a curing agent and a thickening agent and 15-40 wt % dispersed flakes of glass, mica, metal or carbon. The flakes are orientated nearly parallel to the surfaces of the sheet and have a thickness of 0.5-10 ~tm, a diameter of 20-1000 [xm (determined assuming that the flakes are circular) and an aspect ratio of 4-1000. Composite material having a slide layer applied by cathode sputtering Bergmann, E. and Brans, J. (Baizers Aktiengeseilschaft, Furstentum, Liechtenstein) US Pat 4 889 772 (26 December 1989) A composite material has at least one cathode sputtered surface layer. This layer consists of a mixture of particles embedded in a matrix of at least one cohesive metallic material with particles of an additional metallic material, the diameters of which vary according to location. The hardness of the layer varies with the particle diameter; regions with small mean particle diameter having high hardness and good load-bearing ability and regions with large mean particle diameter having low hardness and good embedding capacity. SiC-AI20 a composite sintered bodies and method of producing the same Niihara, K. and Nakahira, A. (NGK Insulators, Ltd, Nagoya, Japan) US Pat 4 889 834 (26 December 1989) A composite sintered body with a fracture toughness of not less than 5 MN m -3~2 consists of a matrix of AI20 3 grains less than 5 ~tm in size with 2-10 tool% SiC grains dispersed inside individual Al20 3 grains. The SiC grains are less than 0.5 ~m in size. Composite material containing a layered silicate Usuki, A., Mizutani, Fukushima, Y., Fujimoto, M., Fukumori, K., Kojima, Y., Sato, N., Kurauchi, T. and Kamigaito, O. (Kabushiki Kaisha Toyota Chuo Kenkyusho, Aicha, Japan) US Pat 4 889 885 (26 December 1989) A composite material comprises at least one resin with a layered silicate uniformly dispersed in the resin. The resin is selected from the group consisting of a vinyl-based polymeric compound, a thermosetting resin and a rubber, and the silicate has a layer thickness of 0.7-1.2 nm and an interlayer distance of 3 nm. At least one resin is connected to the layered silicate through an intermediate there between.
Titanium diboride-based composite articles with improved fracture toughness Buljan, S.-T.V. and Geary, E.G. (GTE Laboratories Incorporated, Waltham, MA, USA) US Pat 4 889 935 (26 December 1989) A densified, hard, abrasion-resistant ceramic-matrix composite article consists of a matrix of titanium diboride with not greater than 60 vol % of dispersoids distributed therein. 5-60 vol % of the dispersoids are whiskers or chopped fibres of refractory carbides, nitrides and carbonitrides of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W and solid solutions thereof and 5-55 vol % are particles of the above or whiskers, fibres or particles of hafnium dihoride, tungsten diboride, silicon nitride, alumina, zirconia, hafnia and mixtures and solid solutions of these materials.
PROCESSES Method of manufacturing glass fibre Nishino, A., Mizuno, Y. and Ikeda, M. (Matsushita Electric Industrial Co, Ltd, Osaka, Japan) US Pat 4 885 020 (5 December 1989) Glass is poured into a mould with a polygonal cross-section slit which is 5-50 times larger than the required thickness of the glass fibre. The glass is cooled and removed from the slit to provide a preform which is heated to a temperature of 100°C to 150°C higher than the softening point of the glass so as to obtain a polygonal cross-section glass fibre which is then cooled. Preparation of metal oxide fibres from intercalated graphite fibres McQuillan, B.W. and Reynolds, G.H. (Secretary of the Air Force, Washington, DC, USA) US Pat 4 885 120 (5 December 1989) AICia, ZrCI4 and C12 are intercalated into a graphite fibre by heating the mixture to 250°C for 4 days. The intercalated graphite fibre is heated in air at 800°C to oxidize the carbon and leave a composite aluminium oxidezirconium oxide fibre. Process for preparing self-supporting bodies and products produced thereby Claar, T.D., Mason, S.M., Pochopien, K.P., White, D.R. and Johnson, W.B. (Lanxide Technology Company, LP, Newark, DE, USA) US Pat 4 885 130 (5 December 1989) A parent metal is heated in a substantially inert atmosphere above its melting point. The molten metal is placed in contact with a permeable mass of boron carbide and at least one donor material selected from the group consisting of a carbon donor material and a boron donor material. The temperature is maintained so that the molten metal infiltrates the permeable mass and reacts with the boron carbide to produce at least one boroncontaining compound and with at least one donor material. The reaction is continued until a self-supporting body comprising at least one parent metal boron-containing compound is produced. Process for preparing self~supporting bodies and products produced thereby Newkirk, M.S. (Lanxide Technology Company, LP, Newark, DE, USA) US Pat 4 885 131 (5 December 1989) A parent metal is heated in a substantially inert atmosphere above its melting point. The